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How to: Prevent a Fire Hazard!

Discussion in 'Stock 1991 - 1994 Explorers' started by gmanpaint, October 2, 2010.

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    1. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Fall time=fire hazard time.

      After a fire happened in the 94, I had to figure out where it started. After a serious freaking out and pulling off the road to a safe spot, I looked everywhere possible, there was no clue to where the fire was. The cabin filled with smoke and had an aroma of a wood fire.

      A phone call was made to a knowledgeable friend and he informed me that a fire can be started in the firewall due to natures debris touching red hot elements on the blower speed control resistor. Apparently the debris from leaves and tree seedlings make their way into the fresh air supply duct work via the hood cowl.

      To remedy this and to prevent this from happening to you, here is how to take care of it.


      Here is the blower location on a 1st gen (91-94). Passenger side on the firewall, next to the A/C Box, behind the air filter box. The resistor is under the heater core hose's attached to the box that looks like it is covered with aluminum foil.

      001.jpg

      Remove the airbox vac lines, (noting their placement for install later), then the air box itself, and place aside. Remove the wire connectors on the blower motor, and the resistor which is attached to the right of the blower and on the A/C box.

      Remove the blower motor with 3-8mm bolts.


      002.jpg


      This is what you have after that.

      003.jpg

      Remove the resistor with 2-8mm bolts.

      Here is the fire starter. The resistor for the blower speed control. This is not used for high speed, only for lower speeds. The coils get red hot like on toaster elements.

      004.jpg

      Here is the fuel for the fire.

      Inside the resistor hole. This is the narrow passage that clogs up and where the fire will start.


      005.jpg

      Inside the blower motor hole.



      006.jpg

      To clean this mess up, I used compressed air to blow it all out into the blower area as best I could, then used a shop vac to remove the debris.

      007.jpg 008.jpg 009.jpg

      Thats it. Reinstall the blower motor, the resistor, connect the wiring, install the filter airbox, and test your blower out.

      I hope this helps somebody here, as this really gave me a good fright and was in a high traffic situation when this occurred.



      :salute:
       
      Last edited by a moderator: March 5, 2018
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    3. huntman58

      huntman58 Active Member

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      good post saw all the junk in mine when I replaced the fan could not belive how much was in there or that it even got in there . glad you were only scared and not left truckless.
       
    4. Slowlyvverot

      Slowlyvverot Active Member

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      looks like i have something to do on the day off tomorrow... :thumbsup:
       
    5. FIND

      FIND Well-Known Member

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      very good post
       
    6. 94explorerEB

      94explorerEB Active Member

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      Holy crap this happened to me with my 92. I didn't think to look in the blower motor case I bet it was full of junk. Though mine only smoked real bad through the vents. I'm gonna check out my 94 this sunday now lol.
       
    7. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      The vents are where the smoke came out for me also, but the weird part it mostly came out the rear console vents, not the defroster vents as I had it set for floor/defrost, so the back filled first. All kinds of things were racing through my head. Not an ideal situation for being in heavy rush hour traffic.
       
    8. ragajungle

      ragajungle Well-Known Member

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      Gotta wonder about the engineers at Ford sometimes. That is crazy! It's like a population control module in there....
       
    9. cybergasm

      cybergasm B

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      nahhh more like we have are own built in Hooka Pipes :D:smokinfro
       
    10. YBCold

      YBCold Well-Known Member

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      thanks for sharing
       
    11. rickybobby

      rickybobby Well-Known Member

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      Great post Gman, and something that so many people overlook too
       
    12. Burns

      Burns Elite Explorer Moderator Emeritus

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      Great post. I need to get on top of this. Mine sounds like it has something in there.
       
    13. AgInternational

      AgInternational New Member

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      wow thanks for the solution. I was scared to death when that happened to me. good thing I am free tomorrow.
       
    14. 92blusilvxlt

      92blusilvxlt Active Member

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      yeah good lookin out.
       
    15. Joe Dirt

      Joe Dirt Explorer Addict

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      Wow- just saw this one... I'll have to check this out!
       
    16. westfield

      westfield Active Member

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      Great informative post ! Wonderful job !
       
    17. johnvosh

      johnvosh Active Member

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      This is something I should do since mine was sitting under some trees for a year before I got it and there is probably a lot of stuff blocking the heater core. Thanks for the good post!
       
    18. F15E_WSO

      F15E_WSO Active Member

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      In other words Joe Dirt is THRILLED that he has something else to clean! :D
       
    19. AgInternational

      AgInternational New Member

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      turns out mine was infested with an old rats nest. some leaves smoldered around the resistor which killed it. I think thats the only part that needs replacing. thank you for saving me from a frosted windshield and now having some air inside. :)
       
    20. dking

      dking Elite Explorer

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      Great Post mine started doing the same thing after I changed out the blower motor I did not see any trash in the blower housing put I will check the resistor housing. Thanks for the info I would have never have checked it without your post.
       
    21. Roadrunner777

      Roadrunner777 Well-Known Member

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      Did this as my first real work on the vehicle. I'm pretty sure I did this entire job with an 8mm socket and an air hose. It was a good introduction... pulling the airbox showed me the spark plugs. If I can get to the spark plugs, then generally the engine and I will get along.
       
    22. Jason94sport

      Jason94sport Well-Known Member

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      Didn't know there was a thread for this. When I replaced the cooling system last month I replaced the resistor. OMG the amount of crap in that box was amazing. Did the same thing.. shop vac time.
      I didn't remove the blower motor though.
       
    23. sector9

      sector9 Active Member

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      Just a question to add Has anybody tried to add a cabin air filter to this system?
       
    24. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      I wouldn't even have a clue as to where to install a filter. :scratch:

      Glad this thread was bumped tho! :thumbsup:

      This is around the time some of us start using the heater/defroster settings. For a lot of us we have another month before we really should be looking into cleaning this out.

      :salute:
       
    25. Xeek

      Xeek Elite Explorer

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      i dont think it needs to be bumped. i think it needs to be stickied.

      i had been meaning to do this, then i didnt have any heat due to heater hose problems. so when i converted to a non-ac box im glad i hadnt used the heater before. it was FULL of leaves/crap.

      i need to do this to my other truck also. and replace the blower thats broken
       
    26. msmith65

      msmith65 Active Member

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      Found this searching for "smoke defroster" because on backing out of the driveway last week I got a column of smoke from the defroster vent, which smelled kind of woodsy (almost like tobacco) and had me totally confused as to what would cause it. The smoke stopped after a few minutes, and everything on the car still worked, so I figured whatever burned had burnt away.

      Now I have a little work ahead of me to get that junk out of there. Thank you for the play-by-play.
       

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